Muffler: Service and Repair

OVERHAUL

IMPORTANT POINT - REMOVING

WARNING: Do not touch the exhaust manifold when it is hot. You can be severely burned.







1. REMOVE THE EXHAUST PIPE FROM THE EXHAUST MANIFOLD.







2. REMOVE THE EXHAUST MUFFLER AND TAIL PIPE.

NOTICE: Removal and installation should be done completely.







IMPORTANT INSPECTION - POINT
1. EXHAUST MUFFLER AND PIPES

NOTICE:
- Be particularly careful of rust holes and dents caused by flying stones.
- If there are holes or cracks in the exhaust muffler and pipe, the exhaust noise will increase and may exceed the EPA noise regulation values. In addition, hot gas may blow out, resulting in the risk of fire.
- If the exhaust muffler and pipe is severely dented by flying stones, etc., the exhaust resistance will increase, causing output decrease and resulting in an increase of fuel consumption.







IMPORTANT POINT - INSTALLATION
1. INSTALL THE EXHAUST MUFFLER AND TAIL PIPE
1. Connect the exhaust pipe and muffler.
2. Tighten the exhaust pipe and muffler 4 nuts to the specified torque.

Tightening Torque: 65-75 N.m {6.6-7.7 kgf.m, 48-55 ft.lbf}

3. Tighten the clamp 2 nuts to the specified torque.

Tightening Torque: 26.5-32.5 N.m {2.7-3.3 kgf.m, 20-24 ft.lbf}

NOTICE:
- When tightening the clamp, first tighten the upper bolt then the lower bolt.
- Removal and installation should be done completely.

WARNING: If the position on the tail pipe is incorrect, exhaust fumes may blow onto passers by and burns may also result.

4. Connect the exhaust pipe to the exhaust manifold. Tighten the 4 nuts to the specified torque.







5. Tighten the 4 nuts to the specified torque.

Tightening Torque: 65-75 N.m {6.6-7.7 kgf.m, 48-55 ft.lbf}

NOTICE:
- Replace the gasket with new one.
- The mounting portion of the exhaust manifold is subjected to heat and is likely to come loose, so special nuts are employed. Be sure to use the correct nuts.







- When fitting the exhaust muffler, seamed part should be directed to the chassis center.






- Fit the clamp to the muffler as shown in the figure.
- Caution when handling and assembling the catalytic muffler. The ceramic part, which is easily broken, is contained inside the muffler. Be careful not to apply shocks to it. Excessive loads, hitting of hard things such as tools etc., onto the edges could cause it to shatter and drop off.